Fluorochemical-containing textile finishes that exhibit wash-durable soil release and moisture wicking properties

ABSTRACT

Wash-durable fluorochemical-containing textile and/or fiber treatments that simultaneously impart soil resistance (or soil-release) properties and moisture wicking characteristics to target fabric substrates are provided. Such treatments surprisingly impart these two simultaneous effects to target fabrics and/or fibers because fluorochemicals generally provide moisture repellency rather than moisture wicking capabilities. As prior soil release/moisture wicking treatments do not function properly, or, alternatively, compromise hand or other properties of certain target textiles after treatment application, a new, effective, soil release/moisture wicking formulation for such purposes was needed. The inventive treatment is extremely durable on such fabric substrates; after a substantial number of standard launderings and dryings, the treatment does not wear away in any appreciable amount and thus the substrate retains its soil release/moisture wicking properties. The method of adherence to the target yarn, fiber, and/or fabric may be performed any number of ways, most preferably through the utilization of a jet dyeing system or through a steam-transfer method. The particular methods of adherence, as well as the treated textile fabrics and individual fibers are also encompassed within this invention.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending applicationSer. No. 10/321,907, filed on Dec. 17, 2002. This parent application isherein entirely incorporated by reference.

FIELD OF THE INVENTION

This invention relates to wash-durable fluorochemical-containing textileand/or fiber treatments that simultaneously provide soil-releaseproperties and moisture wicking characteristics. Such treatmentssurprisingly impart these two simultaneous effects to target fabricsand/or fibers because fluorochemicals generally provide moisturerepellency rather than moisture wicking capabilities. As prior soilrelease/moisture wicking treatments do not function properly, or,alternatively, compromise hand or other properties of certain targettextiles after treatment application, a new, effective, soilrelease/moisture wicking formulation for such purposes was needed. Theinventive treatment is extremely durable on such fabric substrates;after a substantial number of standard launderings and dryings, thetreatment does not wear away in any appreciable amount and thus thesubstrate retains its soil release/moisture wicking properties. Themethod of adherence to the target yarn, fiber, and/or fabric may beperformed any number of ways, most preferably through the utilization ofa jet dyeing system or through a steam-transfer method. The particularmethods of adherence, as well as the treated textile fabrics andindividual fibers are also encompassed within this invention.

DISCUSSION OF THE PRIOR ART

There has been a tremendous effort over many years to bring aboutacceptance of textiles comprising synthetic fibers therein, particularlywithin the apparel, napery, and other like market areas (such as withinany of the following U.S. patents: U.S. Pat. Nos. 3,377,249; 3,540,835;3,563,795; 3,574,620; 3,598,641; 3,620,826; 3,632,420; 3,649,165;3,650,801; 3,652,212; 3,660,010; 3,676,052; 3,690,942; 3,897,206;3,981,807; 3,625,754; 4,014,857; 4,073,993; 4,090,844; 4,131,550;4,164,392; 4,168,954; 4,207,071; 4,290,765; 4,068,035; 4,427,557; and4,937,277; these patents are accordingly incorporated herein byreference). In particular, polyester-based fabrics, being inexpensiveand available in large supply, have required modifications to impartmoisture wicking properties (either for wearer comfort for apparelfabrics or, for uses such as napery, for the ability to permit adhesionof unwanted liquids or other spills to prevent transfer to a user'sclothing or skin) as well as soil release characteristics (for an easein cleaning the particular fabric substrate). Generally, as alluded toabove, such synthetic fibers, yarns, and/or fabrics, particularly thoseincluding polyester, do not exhibit such moisture wicking and soilrelease properties. Thus, there exists the need to modify such syntheticfabrics (or at least fabrics comprising at least some syntheticcomponents, as in polyester/cotton blends, as one non-limiting example).

However, even with the ability to impart such necessary properties to atarget synthetic-yarn-containing fabric, other concerns must be met. Forexample, hand, the general feel and texture of a textile, is of greatimportance with many fabric end-uses. The application of certain surfacetreatments can deleteriously affect hand characteristics even ifmoisture wicking and soil release properties are supplied. Thus, it isimperative that any surface modifying treatments impart desirablechemical characteristics while also not compromising the hand or otherlike physical property of the target synthetically based fabric.Furthermore, since most, if not all, end-uses for such syntheticallybased fabrics require laundering for removal of staining and soilingthereon, it is also imperative that such fabrics exhibit wash durabilityin that the surface modifying treatments are not easily removed throughuse and/or laundering and ultimately exhibit long-term reliable soilrelease, moisture wicking, and hand characteristics (at the very least)to permit cost-effective use of such fabrics to the purchaser.

Of major concern has been the difficulty of cleaning fabrics made frompolyester fibers using conventional home and/or industrial washingprocedures due to the oleophilic nature of the garments made fromtextile materials of polyester fibers. Thus, numerous efforts have beenproposed to alter the oleophilic properties of the textile materialproduced from polyester fibers so that dirt and/or oily deposits on thesoiled textiles can readily be removed by such a home washing procedure.However, in altering the oleophilic characteristics of the textilematerial care must be exercised to insure that the hand of the fabricdoes not become hard which would result in discomfort to the wearer oruser of the target fabric.

In attempting to solve the problem of soiling in synthetic fabrics asubstantial amount of research has been conducted in the past as aresult thereof. Further, much effort has been directed to the use ofblends containing synthetic fibers and naturally occurring fibers inorder to produce a resulting blend which possesses the desired soilrelease properties and the desired hand properties. Thus, attempts havebeen made to reduce the oleophilic characteristics of synthetic fibers,such as polyester, by coating the fibers with a coating that isoleophobic, i.e., one that will hinder the attachment of soil or oilymaterials to the fiber. Many polymer systems have been proposed whichare capable of forming a film around the fibers that constitute thetextile material, particularly acid emulsion polymers prepared fromorganic acids having reactive points of unsaturation. Typical of suchacid emulsion polymers is set forth in U.S. Pat. No. 3,377,249 whereinsoil release and durable press characteristics of linear polyesterfibers are improved by application of an admixture comprising anamino-plast textile resin, a textile resin catalyst and a synthetic acidemulsion polymer. The resulting resin composition, so applied, isthereafter cured.

In addition, efforts have been made to improve the soil releasecharacteristics of synthetic fibers during the conventional home washingoperation. Such a process is set forth in U.S. Pat. No. 3,798,169wherein a polycarboxylate polymer having an acid equivalent weight offrom about 110 to 175 is precipitated from a dilute solution containingsuch polymer by the use of a water soluble salt of a polyvalent metal.Thus, the solution polymer is caused to be deposited upon the fabricduring the final rinse cycle in the home cleaning process.

However, even in view of the above and numerous other processes andcompositions which have heretofore been advanced by the prior artresearch is constantly being conducted to develop new and improvedcompositions and processes for imparting durable source soil releasecharacteristics to polyester fibers and to textile materials formedtherefrom so that garments made of polyester textile materials canreadily be cleaned in both a home washing operating and a commercialcleaning process. Accordingly, by virtue of the teachings of the presentinvention, problems historically present with the use of garmentsproduced from textile materials of polyester fibers are substantiallyalleviated and a durable soil release characteristic is achieved.

As non-limiting examples of the aforementioned hand problem, certain newfabrics comprised of synthetic fibers in configurations such as tightlywoven filament fabric, spun-containing fabric, microdenier fabric, flatfabric, and nonwoven (filament, microdenier, and/or staple fibers)fabric structures, have been traditionally provided or recentlydeveloped that exhibit effective moisture wicking and excellent handproperties. In particular, the tightly woven filament fabric and/or spunyarn-containing fabric appear to provide levels of hand heretoforeunforeseen, particularly for polyester-based textiles. Unfortunately,the soil release characteristics of such woven and nonwoven types offabric as noted above are lacking to the degree necessary to permitwidespread use (for napery purposes, for example). As noted above, thereare typical polyester treatments (such as U.S. Pat. Nos. 3,798,169 and3,377,249, as examples) that impart the aforementioned desired chemicaland physical attributes to certain target textured polyester-basedfabrics; however, these particular types of problematic woven and/ornonwoven fabrics noted above (e.g., tightly woven filament fabric and/orspun yarn-containing fabric) are not compatible with such traditionalpolyester treatments such that either the treatment lacks the necessarydurability (of either the soil release or moisture wicking properties)or the treated fabric's hand properties are compromised to too great adegree for proper utilization by the end-user. Furthermore, in somesituations, the needed levels of moisture wicking and soil releaseproperties are unavailable unless the target fabrics are firstindustrially washed, only to lose such characteristics soon thereafter.

There is thus a need to provide a new type of treatment for theeffectuation of such needed soil release and moisture wickingcharacteristics to synthetically based fabrics that also does notdeleteriously affect the hand or other like property or properties ofthe same target fabric, all with a wash durability that exceeds thestandard level (i.e., 5 standard industrial launderings, or, preferablyat least 10-20 such launderings). To date, the only treatment types thathave met this specific previous uses have been based upon amino-plast,polycarboxylate acid, sulfonated and/or ethoxylated polyester, and othertypes of technology. To date, no surface modification treatments havebeen developed specifically with tightly woven filament fabric, spunyarn-containing polyester fabric, polyester microdenier fabric,synthetic nonwoven fabric, synthetic flat fiber-containing fabric, andthe like, in mind, nor, for that matter, that include fluorine-basedchemicals for that or for any other purpose, with the end-product beinga fabric that meets all of the above-discussed all-importantrequirements for synthetically based fabrics. There is thus a great needfor such a particular surface modification treatment formulation andapplication to synthetically based fibers, yarns, and/or fabrics.

DESCRIPTION OF THE INVENTION

It is therefore an object of the present invention to provide a textilematerial formed of tightly woven synthetic filament fabric and/or spunyarn-containing polyester fabric (or any of the other unique fabricconstructions noted previously) exhibiting wash-durable soil release andmoisture wicking characteristics with acceptable hand levels. Stillanother object of the present invention is to provide a process forimparting durable soil release characteristics to such specific textilematerials formed of spun synthetic yarn, tightly woven filamentpolyester fibers, microdenier polyester fibers, nonwoven syntheticfibers, flat non-textured synthetic fibers, and any blends with eachother or with other types of natural or synthetic fibers. Additionally,a further object is to provide a fluorochemically based textiletreatment formulation that imparts such desirable wash-durablecharacteristics to synthetically based fabrics.

Accordingly, this invention encompasses a treated textile substratecomprising at least 25% by weight of synthetic fiber component(preferably at least 50%, more preferably at least 75%, and mostpreferably all synthetic fiber), wherein said substrate is treated withat least one fluorochemical, wherein said substrate exhibits a soilrelease property in excess of or equal to 3.0 as measured by AATCC TestMethod 130-2000 and a moisture wicking property less than or equal to 10seconds, preferably less than or equal to 6, as measured by a water-dropsurface spreading test protocol; wherein said soil release property andsaid moisture wicking properties are exhibited by said substrate afterexposure to at least 5 industrial launderings (the protocol for whichdefined below in greater depth). Also, and alternatively, this inventionencompasses a treated textile substrate comprising at least 25% ofpolyester fibers wherein said fibers are present within said substratein a configuration selected from the group consisting of tightly wovenfilament synthetic yarns, spun synthetic yarns, synthetic microdenieryarns of at most an average denier of 1.0, nonwoven synthetic fibers,flat non-textured synthetic yarns, and blends of any such yarns witheach other or with any other type of natural or synthetic fibers oryarns; wherein said substrate exhibits a soil release property measuredas wherein said substrate exhibits a soil release property in excess ofor equal to 3.0 as measured by AATCC Test Method 130-2000 and a moisturewicking property less than or equal to 10 seconds, preferably less thanor equal to 6, as measured by a water-drop surface spreading testprotocol; wherein said soil release property and said moisture wickingproperties are exhibited by said substrate after exposure to at least 5industrial launderings. Such an invention also encompasses the differentmethods of producing such inventive treated substrates. The washdurability test noted above is standard and, as will be well appreciatedby one of ordinary skill in this art, is not intended to be a requiredor limitation within this invention. Such a test method merely providesa standard which, upon 5 washes (and preferably more, such as in excessof 10, and more preferably even higher, such as 20, such industrialwashes) in accordance with such, the inventive treated substrate willnot lose an appreciable amount of its soil release and/or moisturewicking finish.

Nowhere within the prior art has such a specific treated substrate ormethod of making thereof been disclosed, utilized, or fairly suggested.The closest art, which fails to disclose the same inventive soil releaseand moisture wicking durable finishes herein taught, includes U.S. Pat.Nos. 3,574,791, 4,007,305, 4,695,488, and 6,383,633.

As certain synthetic components are required within the inventivetextile substrates, any such synthetic yarns, fabrics, or films may beutilized as the substrate within this application. Thus, any ofpolyesters, polyamides, polyolefins, polyaramides, and the like, orcombinations of these fiber types, or, alternatively, blends withnatural fibers, such as cotton, wool, ramie, and the like, mayconstitute the target substrate. As for the required synthetic types,for instance, and without intending any limitations therein,polyolefins, such as polyethylene, polypropylene, and polybutylene,halogenated polymers, such as polyvinyl chloride, polyesters, such aspolyethylene terephthalate, poly(lactic acid), and poly(butyleneterephthalate), polyester/polyethers, polyamides, such as nylon 6 andnylon 6,6, polyurethanes, as well as homopolymers, copolymers, orterpolymers in any combination of such monomers, and the like, may beutilized within this invention. Nylon-6, nylon-6,6, polypropylene, andpolyethylene terephthalate (a polyester) are particularly preferred.Additionally, the target fabric may be coated with any number ofdifferent films, including those listed in greater detail below.Furthermore, the substrate may be dyed or colored to provide otheraesthetic features for the end user with any type of colorant, such as,for example, poly(oxyalkylenated) colorants, as well as pigments, dyes,tints, and the like. Other additives may also be present on and/orwithin the target fabric or yarn, including antistatic agents,brightening compounds, nucleating agents, antioxidants, UV stabilizers,antimicrobial agents, fillers, permanent press finishes, softeners,lubricants, curing accelerators, and the like.

The particular treatment must comprise at least one type offluorochemical compound to impart the needed soil release property aswell as at least one other compound and/or polymer that imparts theneeded moisture wicking characteristics thereto simultaneously. Theproblems of utilizing fluorochemical treatments in the past in such aspecific moisture wicking application is that such components areinherently and greatly water repellent. As a result, the ability of sucha fluorochemical treatment in the past to impart the needed simultaneoussoil release and moisture wicking properties were, to say the least,nonexistent, at least to the extent that industrial wash durability isexhibited simultaneously. The closest art teaches at best initialnon-washed simultaneous soil release and moisture wicking properties forfluorochemical-containing textiles finishes; however, such finishes arenon-durable and are easily removed once industrial washing isaccomplished.

Surprisingly, it has now been found that certain combinations andapplication procedures of such a fluorochemical component and theabove-noted at least one other moisture wicking compound and/or polymercan actually be applied to fabric substrates and surfaces to the extentthat the desired dual-property (soil release and moisture wicking)result can be achieved, particularly on a wash-durable basis. Again, inthe past, it has been in essence an insurmountable problem to apply sucha fluorochemical treatment to synthetic fabric substrates and achieve amoisture wicking result. Thus, there was no rational basis for theordinarily skilled artisan within this particular art to utilize suchfluorochemical treatments for moisture wicking end-uses, no matter howacceptable such treatments were in terms of soil releasecharacteristics. However, the advent of new tightly woven and/or spunyarn polyester fabric applications, and the difficulty of durablytreating such substrates with typical prior soil release/moisturewicking treatment formulations has led to the discovery that certaincombinations and/or treatment procedures not only permit, but apparentlyrequire, fluorochemically based treatments for proper application of anysuch soil release technology to at least these specific tightly wovenand/or spun yarn-based polyester fabric substrates. Thus, utilizing thisspecific end-use fabric as a starting point, it has further beenrealized that other end-use fabrics may be treated with suchfluorochemically based treatments to impart these durable properties todifferent textiles as well.

The term fluorochemical in terms of this invention is thus intended toinclude any compound and/or polymer, including at least one monomer orpendant group containing at least one moiety having a carbon-fluorinebond therein, that imparts industrial wash durability soil releaseproperties to synthetic fibers (polyesters, as one non-limitingexample). Non-limiting, though preferred fluorochemicals of this typeinclude compounds and/or polymers including the aforementioned at leastone carbon-fluorine-containing moiety and pendant groups or monomers ofa hydrophilic nature. Generally, fluorinated compounds and/or polymersdo not exhibit textile surface soil release properties unless suchhydrophilic groups or monomers are actually present thereon. Ahydrophilic monomer or pendant group (such as an acid functionality,acid salts, base functionality, amides, urethanes, hydroxyls, anoxyalkylenated group, and the like, as non-limiting possibilities) maybe present thereon in order to provide some degree of hydrophilicity.Most soil release fluorochemicals of this nature includefluorine-containing acrylate copolymers, urethanes, amide copolymers,polyethers, sulfonyl amides, and the like, within the fluorochemicalcompound and/or polymer. In general, however, the fluorinated portion ofsuch a component will dominate in terms of soil repellency (as comparedwith soil release) (and thus potential hydrophobicity of the entirestructure) to the extent that the needed soil release characteristicsare provided via this fluorochemical in tandem with the necessaryhydrophilic portions included therein the compound and/or polymer. Somespecific, again non-limiting, though preferred fluorochemical polymersare available from Daikin under the tradenames of Unidyne® TG-992 andUnidyne® TG-993, as well as from Mitsubishi under the tradename Repearl®SR-1100. Other possibilities as fluorochemical components for thisinventive finish include, again, without limitation, and merely providedas potentially preferred materials for such a purpose, Zonyl® 7910 or9200 (both from DuPont), FC-258 or PM-490 (both from 3M), and Baygard®SOC or WSR (both available from Bayer). Such fluorochemicals arebelieved to exhibit some hydrophilic portions thereon as well as highlydesirable soil release capabilities for synthetic fabrics. Again, otherfluorochemical compounds and/or polymers may be utilized within thisinventive formulation as long as such a fluorochemical imparts therequisite level of soil release characteristics to the target syntheticfiber-based fabric.

Such a fluorochemical component thus accords the necessary soil releaseproperties. However, there remains the necessity of according,simultaneously, a wash durable moisture wicking characteristic as well.This has been accomplished through the inclusion of a number ofdifferent alternatives or combinations of typical hydrophilic polymerictreatments simultaneously to the target fabric with the aforementionedfluorochemical. Such hydrophilic agents include, without limitation,ethoxylated polyesters, sulfonated polyesters, cellulose ethers,ethoxylated polyamides, copolymers of vinyl acetate and hydrophiliccrosslinking agents, among other potential hydrophilic components.Specifically, such additives are commercially available under thetradenames of Eastman WD Size, Lubril QCX, also from Eastman Chemical,Methocel® A-LV from Dow Chemical, and the like. These preferred, thoughnon-limiting, examples have been found to provide excellent moisturewicking properties to the target synthetic fiber-based fabric even inthe presence of the required soil release fluorochemical polymer. Thesehydrophilic components are generally present in aqueous dispersions(with from about 5-60% solids content; preferably, from 10-40% solidscontent; and most preferably between about 12-20% solids content).

In particular, it has been found that exhaustion of these two componentssimultaneously on the target synthetic-based fabric surface imparts thepreferred performance levels of both soil release and moisture wickingto the industrial wash durability levels required for long-termeffective utilization thereof by the end-user. Particularly preferred,though, again, non-limiting, is the application of such amulti-component finish treatment on target fabrics via a jet dyeingapplication method. Utilization of such a jet dyeing application hasheretofore not been followed in order to impart such characteristics tofabrics through fluorochemical finishes (at least), let alonesynthetically based fabrics, due to costs and generally non-acceptanceof such a required process step when simple padding methods were morecost-effective and reliable with non-fluorochemical-containing polyester(and other like synthetic fabric) treatment formulations. Withoutintending on being bound to any specific scientific theory, it isbelieved that such a jet dye application method permits enmeshment ofthe two required components at the target fiber and fabric surfacesthereby providing a treatment wherein a theoretical equal number ofsites for atmospheric exposure for the fluorochemical (and thus soilrelease property) and the hydrophilic additive (and thus moisturewicking property) can exist simultaneously. In such a manner, it isbelieved that an optimum level of both properties may be achieved to theextent that soil release characteristics will be imparted throughcontact at the fluorochemical-exposed sites with a similar number (atleast in theory) of hydrophilic-agent-exposed sites. Thus, complete soilrelease over the entire fabric may not actually occur; but, with such atheorized enmeshment of both components in this manner, the actualeffect is that substantial soil release over a vast actual majority, ifnot a basic perceived majority, of the target fabric is achieved.Likewise, this apparent phenomenon is available for the moisture wickingcomponent as well.

Additionally, however, it has been found that certain reliable resultsare also available, though to a lesser extent, particularly in terms ofdurability, for padded-on blends and/or combinations of both of theseparticular components. Application of a first layer followed by thenext, however, results in either soil release, moisture repellentfinishes at the surface, or hydrophilic treatments located at thesurface that result in a lack of wash durability for the finish itself.Further alternatives of application of this inventive treatmentformulation include, without limitation, simultaneous pad coating (suchas, for example, pad steaming), screen coating, spraying, andkiss-coating (particularly for yarn applications). Again, though, itappears that simultaneous application of these two components isrequired to effectuate the needed industrial wash durable levels of soilrelease and moisture wicking.

The proportions of the needed components are quite broad in scope,ranging from 0.05 to about 10% by weight of the fluorochemicalcomponent, with lower amounts preferred (from about 0.05 to about 5%,and most preferably from about 0.1 to about 2.5%, all in terms of solidsadd-on on the target fabric). The hydrophilic component should bepresent in roughly the same basic ranges of amounts (and a substantially1:1 weight ratio of the two components is most preferred, with lesspreferred ratios of from 0.5:5 to 5:0.5 and any ratio in between) as thefluorochemical component, with some differences such that the preferredrange is from 0.05 to about 10%, more preferably from 0.05 to 5%, andmost preferably from 0.3 to about 2% (again, all in terms of solidsadd-on on the target fabric). The treatments should also include asolvent for dissolution, dispersion, or other like purpose, with arelatively low flash point to permit evaporation after target fabric oryarn surface application. Thus, water, C₁-C₈ alcohols, and the like, maybe present for this purpose, preferably in amounts of from 50 to about99% by weight of the entire formulation. Again, as noted above, otheradditives may be present as well for various reasons (dispersion, forexample) and to achieve certain peripheral results.

The selected substrate may be any of an individual yarn, a fabriccomprising individual fibers or yarns (though not necessarily previouslycoated yarns), or a film (either standing alone or as laminated to afabric, as examples). The individual fibers or yarns may be of anytypical source for utilization within fabrics, including natural fibers(cotton, wool, ramie, hemp, linen, and the like), synthetic fibers(polyolefins, polyesters, polyamides, polyaramids, acetates, rayon,acrylics, and the like), and inorganic fibers (fiberglass, boron fibers,and the like). The target yarn may be of any denier, may be of multi- ormono-filament, may be false-twisted or twisted, or may incorporatemultiple denier fibers or filaments into one single yarn throughtwisting, melting, and the like. The target fabrics may be produced ofthe same types of yarns discussed above, including any blends thereof.Such fabrics may be of any standard construction, including knit, woven,or non-woven forms.

The yarns are preferably incorporated within specific fabrics, althoughany other well known utilization of such yarns may be undertaken withthe inventive articles (such as tufting for carpets). The inventivefabrics may also be utilized in any suitable application, including,without limitation, apparel, upholstery, bedding, wiping cloths, towels,gloves, rugs, floor mats, drapery, napery, bar runners, textile bags,awnings, vehicle covers, boat covers, tents, and the like. The inventivefilms may be present on fabrics, or utilized for packaging, as coatingsfor other types of substrates, and the like.

PREFERRED EMBODIMENTS OF THE INVENTION

Fluorochemical Treatments

The preferred fluorochemically based treatment will generally comprisethree required components: the fluorochemical, the moisture wickingcomponent, and a solvent (with any number of other additives availableas well, as noted above). Such a fluorochemically based treatment isgenerally produced and applied to a fabric substrate by first cleaningand prepping the target fabric and subsequently placing the fabric in ajet dyeing apparatus (from Werner Mathis) (as is most preferable forminijet procedures, though not limiting by any means, for thisinvention) for simultaneous dyeing and applying of the fluorochemicaltreatment to the target fabric. The particular fluorochemical treatmentformulations are provided below for which application and subsequenttreated fabric analysis was then followed. Each jet-dyed sample belowincluded a standard dye formulation to impart a forest green color (withCIELAB measurements of L=36.24, a=−17.90, b=6.31, l=2, and c=1) to thetarget fabric. Such a green color result provide a very difficultsubstrate to impart proper soil release properties thereto because ofthe susceptibility of such a color to indicate the presence of soils andstains thereon.

Thus, this formula was applied to each fabric sample below, either priorto application of the finish or simultaneously therewith (unless markedwith an * below, each soil release agent and hydrophilic agent listedbelow is actually present within aqueous dispersions and include nofurther additional solvent; those marked with an * below included addedwater to permit pad treatment therewith). COMPOSITION TABLE 1Fluorochemical Treatment Formulations Soil Release HydrophilicFormulation # Agent (% owf) Agent (% owf) A   1% UnidyneTG-992   2%Lubril QCX B   2% Unidyne TG-992   2% Lubril QCX C   2% Repearl SR-1100  2% Lubril QCX D   1% Unidyne TG-992   5% Eastman WD Size* E 3.5%Unidyne TG-992 3.5% Lubril QCX* F   2% Unidyne TG-992 None G None   2%Lubril QCX H   6% Unidyne TG-992   6% Lubril QCX (Comparatives) I(Control) None None J   2% Unidyne TG-993 None* K   5% Unidyne TG-992None*all weights for this example are by weight of the entire pad bathThese formulations were then applied to target fabrics, the particularlypreferred, non-limiting types being described in depth below, with soilrelease and moisture wicking properties of such treated samples thenassessed at different wash intervals. The hydrophilic agents from abovewere all present as aqueous dispersions with ˜15% solids contenttherein.

The particular fabric substrate was a new one as defined within U.S.patent application Ser. No. 10,304,176, to Love. Specifically, thetarget fabric was defined as follows (and referred to below as FabricI):

A 100% polyester filament plain weave fabric was provided. The fabrichad 1/300/136 false twist texture yarns in the warp direction, and3/150/68 false twist textured yarns in the filling direction, and it waswoven with 60 ends per inch and 46 picks per inch. The fabric wasprepared and dried in a conventional manner.

The fabric was then sanded using an apparatus of the variety describedcommonly-assigned U.S. Pat. No. 6,233,795, the disclosure of which isincorporated herein by reference. The fabric was fed to abrasive rollsin a face-up configuration at an initial tension of 110 psi and a speedof 20 yards per minute. The fabric was treated on its face by successivetreatment rolls at a tension of 300 psi. The abrasive rolls were 400grit diamond plated rolls of the variety described in theabove-referenced patent. The abrasive rolls were turned in a clockwiseor counterclockwise direction at a designated percentage of machinespeed: the first rotated counterclockwise at a roll ratio of 1800, thesecond rotated clockwise at a roll ratio of 1780, the third rotatedcounterclockwise at a roll ratio of 1800, and the fourth rotatedclockwise at a roll ratio of 1780. The back of the fabric was thentreated by successive rolls as well; the first rotated clockwise at aroll ratio of 2000, the second rotated counterclockwise at a roll ratioof 1980, the third rotated clockwise at a roll ratio of 2000, and thefourth rotated counterclockwise at a roll ratio of 1980. The tensiontherein at the last roll was 150 psi.

The fabric was then processed in a fluid treatment apparatus of thevariety described in commonly-assigned U.S. patent application Ser. No.09/344,596 to Emery et al.

The fabric, which was 78 inches wide and had a weight of about 6 oz/sqyd, was pulled through the pad and hydraulically processed at a speed of80 yds/min. The first treatment zone hydraulically treated the frontside of the fabric at an energy level of 0.037 hp-hr/lb, and theopposite side of the fabric was then treated at an energy level of 0.022hp-hr/lb, for a total treatment of 0.059 hp-hr/lb. The fabric was driedand taken up in a conventional manner. The fabric had a finished weightof 6 oz/sq yd.

An alternative spun yarn polyester product (Fabric II, below) was alsoproduced for treatment that was first treated within the same fluidtreatment apparatus as noted above within the Emery et al. patentapplication ('596). This particular fabric is 100% polyester and is madeof spun warp yarns and filament fill yarns. The fabric is constructed asa plain weave and has 55 ends per inch and 44 picks per inch in thegreige state. The warp yarn is an open end spun 12/1 (i.e. a 12 singlescotton count yarn) with a twist multiple of 3.6, and the filamentfilling yarn is a 2/150/34 (i.e. 2 plies of 150 denier yarn, each plycontaining 34 filaments) and is an inherently low-shrinkage fillingyarn. The greige fabric without size weighs about 5.65 ounces per squareyard.

The above fabric is subjected to the following processing. One side ofthe fabric is subjected to high-pressure water at about 1400 p.s.i.g.(manifold exit pressure) The water originates from a linear series ofnozzles which are rectangular (0.015 inches wide (fillingdirection)×0.010 inches high (warp direction)) in shape and are equallyspaced along the treatment zone. There are 40 nozzles per inch along thewidth of the manifold. The fabric travels over a smooth stainless steelroll that is positioned 0.110 inches from the nozzles. The nozzles aredirected downward about five degrees from perpendicular, and the waterstreams intersect the fabric path as the fabric is moving away from thesurface of the roll. The tension in the fabric within the firsttreatment zone is set at about 35 pounds.

In the second treatment zone, the opposite side of the fabric is treatedwith high-pressure water that originates from a similar series ofnozzles as described above. In this zone the water pressure is about 700p.s.i.g., the gap between the nozzles and the treatment roll is 0.160inches, and the nozzles are directed downward about three degrees fromperpendicular. As before, the water streams intersect the fabric path asthe fabric is moving away from the surface of the roll. The fabrictension between the treatment zones is set at about 60 pounds, and thefabric exit tension is set at about 60 pounds. Maintenance of thesespecific tension levels is preferred, but is not necessarily critical toachieve an acceptable result.

The fabric is dried and then subjected to a variety of finishingchemicals. It is pulled to the desired width in a tenter frame, and thefinished weight is about 6.25 ounces per square yard. Fabrics havingfinished weights between about 5 ounces per square yard and about 9ounces per square yard, and preferably between about 6 ounces per squareyard and about 8 ounces per square yard, and most preferably betweenabout 6 ounces per square yard and about 7 ounces per square yard, havebeen found to be particularly suitable in napery uses.

The treated fabric samples below thus all pertain to this specificnon-limiting, preferred filament synthetic-yarn-containing fabric withdifferent treatment formulations and procedures (in terms of additives,temperatures, exposure times, and the like, followed at times). The jetdyeing application method basically meets the following process steps:

Dye Cycle

a) Heat to 130 degrees Celsius

b) Hold for 30 minutes at 130 degrees

c) Cool to 40 degrees Celsius

d) Decant the liquor and remove the fabric therefrom

The following examples thus indicate the treatment application procedurefor each particular fabric sample Examples 1-7 and the ComparativeExamples were applied to Fabric I; Example 8 was applied to Fabric II):

EXAMPLE 1

The clean and prepped fabric from above was jet treated within a GastonFutura single port plant jet (via the Dye Cycle noted above) withFormulation A and was then dried and heatset at 390° F. for ˜1 minute.

EXAMPLE 2

The clean and prepped fabric was jet treated and treated as in Example1, above, but with inventive treatment Formulation B.

EXAMPLE 3

The clean and prepped fabric was jet treated and treated as in Example1, above, but with inventive treatment Formulation C.

EXAMPLE 4

A small, clean and prepped fabric sample (˜17″×24″), from above, wassoaked in a solution of Formulation D briefly before being nippedbetween a rubber and a steel roll at 40 psi resulting in a wet pick-upof ˜65% (“pad treated”). The fabric was then stretched on a pin frameand dried at 300 degrees Fahrenheit for 4 minutes and heatset at 375degrees Fahrenheit for 2 minutes in a lab convection oven.

EXAMPLE 5

The clean and prepped fabric was treated as in Example 4, above, withFormulation E and dried and heatset to a width of 65″ at 390 degreesFahrenheit for ˜1 minute exposure.

EXAMPLE 6

The clean and prepped fabric was placed in a Werner Mathis mini-jet tosequentially treat with a soil releasing fluorochemical then dye andtreat the fabric with a hydrophilic agent. The soil releasingfluorochemical (Formulation F) used was thus first applied withsubsequent addition of Formulation G. The fabric was removed from thejet and dried and heatset to a width of 65″ at 390 degrees Fahrenheitfor ˜1 minute exposure.

EXAMPLE 7

The clean and prepped fabric was placed in a mini-jet to sequentiallydye and treat with a hydrophilic agent then treat the fabric with a soilreleasing fluorochemical. The hydrophilic agent (Formulation G) used wasthus first applied with subsequent addition of Formulation F. The fabricwas removed from the jet and dried and heatset to a width of 65″ at 396degrees Fahrenheit for ˜1 minute exposure.

EXAMPLE 8

The clean and prepped fabric was jet dyed and treated as in Example 1,above, but with inventive treatment Formulation H.

COMPARATIVE EXAMPLE 1 (CONTROL)

The clean and prepped fabric was placed in a Gaston County Futura(single port) plant jet to dye the fabric using Comparative FormulationI. The fabric was removed from the jet and dried and heatset to a widthof 65″ at 390 degrees Fahrenheit for ˜1 minute exposure.

COMPARATIVE EXAMPLE 2

The clean and prepped fabric was pad treated using the same procedureoutlined in Example 4, above, to treat the fabric with the comparativesoil releasing fluorochemical alone (Formulation J). The fabric wasremoved from the jet and dried and heatset to a width of 65″ at 390degrees Fahrenheit for ˜1 minute exposure.

COMPARATIVE EXAMPLE 3

The clean and prepped fabric was placed in a mini-jet to dye and treatthe fabric with a the soil releasing fluorochemical alone (FormulationK). The fabric was removed from the jet and dried and heatset to a widthof 65″ at 390 degrees Fahrenheit for ˜1 minute exposure.

The resultant inventive and comparative fabrics were then tested forwash durable soil release (corn oil) and moisture wicking (dropletsurface dispersion) properties. Such test protocols were as follows:

Soil Release

Soil release testing followed the procedure outlined in AATCC #130-2000, with the exception that the wash procedure was modified to aharsher, industrial level laundering process. More specifically, thetesting can be broken into three separate steps—staining, washing, andrating. The staining step involved the application of 5 drops of liquidstaining compound (Mazola® corn oil for this particular test, althoughother liquids, such as mustard, etc., could also be utilized) onto thesame location on the fabric surface, which was resting on a sheet ofblotting paper to absorb the excess liquid passing through the fabric.The stain was covered with a sheet of glassine paper and a 5 poundweight was applied for 60 seconds. A 23 pound dummy load of likeuntreated polyester fabric plus the treated fabric sample from theExamples above was then washed in a Milnor 35 pound capacity industrialwashing machine in accordance with the following wash procedure:

Wash Procedure

-   -   a) Flush with 120 degree Fahrenheit water for 3 minutes    -   b) Add 6 oz Flo-Kon® and 3 oz Flo-Sol® to 160 degree F. water        and wash for 18 minutes    -   c) Rinse with 140 degree F. water for 2 minutes    -   d) Rinse with 120 degree F. water for 2 minutes    -   e) Rinse with 100 degree F. water for 2 minutes    -   f) Add sour (½ oz of Flo-New®) and wash for 8 minutes at 90        degrees    -   g) Extract for 5 minutes

The Flo-Kon, Flo-Sol, and Flo-New additives are all commerciallyavailable from U.N.X., Inc. The staining step was followed prior to eachsubsequent test wash to determine the durable nature of the finish tofacilitate soil release as needed during the useful life of the targetfabric article.

The fabric was then tumble dried for 25 minutes on high heat in aHuebsch Originators 50 industrial dryer and was then rated using theAATCC Test Method 130-2000 standard rating system between 1 and 5. Arating of one indicates a highly visible stain and a rating of 5represents a stain that was completely removed. The data in the tablesbelow represent an average of five sample assessments each.

Water Droplet Wicking

Water droplet wicking (or just wicking) tests were conducted by placinga drop of water on the fabric surface and measuring the time in secondsrequired for the reflective water surface to completely disappear.

The results for such testing protocols were as follows: TABLE 1 Mazola ®Corn Oil Soil Release of Treated Samples Rating After X Washes (StainAfter X-1 Washes) Example X = 1 X = 5 X = 10 X = 20 1 3.0 4.0 4.0 3.5 24.0 4.2 4.2 3.5 3 3.7 3.7 3.0 — 4 5.0 — 3.0 — 5 4.5 4.0 4.0 2.0 6 5.05.0 5.0 3.7 7 3.5 3.0 3.0 — 8 4.0 — 4.0 — Comparative 1 1.5 1.5 1.5 —Comparative 2 4.0 — 2.0 — Comparative 3 4.5 3.7 3.7 3.7

TABLE 2 Water Droplet Wicking (seconds) of Treated Samples Wicking TimeAfter X Washes Example X = 0 X = 4 X = 9 X = 19 1 4 2 1 <1 2 6 <1 <1 <13 4.5 <1 <1 — 4 3 — 2 — 5 <1 — 5 <1 6 >10 — >10 — 7 >10 1 1 — 8 1 1.5 2— Comparative 1 1 1.5 2 — Comparative 2 >20 — <1 — Comparative3 >20 >20 >20 >20 

Thus, the inventive fluorochemically based fabric treatments providednoticeable and unexpected simultaneous wash-durable moisture wicking andsoil release properties for synthetically based textiles.

There are, of course, many alternative embodiments and modifications ofthe present invention which are intended to be included within thespirit and scope of the following claims.

1. A method of treating a textile article comprising the steps of a)providing a textile article; b) providing a finish formulationcomprising at least one soil release fluorochemical and at least onehydrophilic agent; and c) applying said finish formulation of step “b”to said textile article.
 2. The method of claim 1 wherein said step “c”is accomplished using an exhaustion procedure.
 3. The method of claim 2wherein said exhaustion procedure utilizes a jet dyeing apparatus. 4.The method of claim 1 wherein said step “c” is accomplished by padcoating.
 5. The method of claim 1 wherein said treated textile articlecomprises at least 25% by weight of a synthetic fiber component.
 6. Themethod of claim 5 wherein said treated article exhibits a soil releaseproperty in excess of or equal to 3.0 as measured by AATCC Test Method130-2000 and a moisture wicking property less than or equal to 10seconds as measured by a water-drop surface spreading test protocol;wherein said soil release property and said moisture wicking propertiesare exhibited by said treated textile article after exposure to at least5 industrial launderings.
 7. The method of claim 5 wherein said textilearticle comprises fibers selected from the group consisting ofpolyesters, polyamides, polyaramides, any blends thereof, any blendsthereof with other synthetic fibers, and any blends thereof with naturalfibers.
 8. The method of claim 7 wherein said fibers are polyester. 9.The method of claim 8 wherein said fibers are present in a configurationselected from the group consisting of spun synthetic yarn, tightly wovenfilament fibers, microdenier polyester fibers, nonwoven syntheticfibers, flat non-textured synthetic fibers, and any blends with eachother or with other types of natural or synthetic fibers.
 10. The methodof claim 1 wherein said hydrophilic agent is selected from the groupconsisting of ethoxylated polyesters, sulfonated polyesters, celluloseethers, ethoxylated polyamides, copolymers of vinyl acetate andhydrophilic crosslinking agents, and mixtures thereof.
 11. A method oftreating a textile article comprising the steps of a) providing atextile article; b) providing a finish formulation comprising at leastone soil release fluorochemical and at least one hydrophilic agent; andc) applying said finish formulation of step “b” to said textile articlethrough an exhaustion procedure.
 12. The method of claim 11 wherein saidstep “c” is accomplished using a jet dyeing apparatus.
 13. The method ofclaim 11 wherein said treated textile article comprises at least 25% byweight of a synthetic fiber component.
 14. The method of claim 13wherein said treated article exhibits a soil release property in excessof or equal to 3.0 as measured by AATCC Test Method 130-2000 and amoisture wicking property less than or equal to 10 seconds as measuredby a water-drop surface spreading test protocol; wherein said soilrelease property and said moisture wicking properties are exhibited bysaid treated textile article after exposure to at least 5 industriallaunderings.
 15. A method of treating a textile article comprising thesteps of a) providing a textile article; b) providing a first finishformulation comprising at least one soil release fluorochemical; c)introducing said textile article of step “a” within a jet dyeingapparatus; d) applying said first finish formulation of step “b” to saidtextile article within said jet dyeing apparatus; e) providing a secondfinish formulation comprising at least one hydrophilic agent; f)introducing said textile article of step “d” within a jet dyeingapparatus; and g) applying said second finish formulation of step “e” tosaid textile article of step “d” within said jet dyeing apparatus. 16.The method of claim 15 wherein said exhaustion procedure is accomplishedusing a jet dyeing apparatus.
 17. The method of claim 15 wherein saidtreated textile article comprises at least 25% by weight of a syntheticfiber component.
 18. The method of claim 17 wherein said treated textilearticle exhibits a soil release property in excess of or equal to 3.0 asmeasured by AATCC Test Method 130-2000 after exposure to at least 5industrial launderings.
 19. A method of treating a textile articlecomprising the steps of a) providing a textile article; b) providing afinish formulation comprising at least one soil release fluorochemicaland at least one hydrophilic agent; and c) applying said finishformulation of step “b” to said textile article via pad coatingtechniques.
 20. The method of claim 19 wherein said treated textilearticle comprises at least 25% by weight of a synthetic fiber component.21. The method of claim 20 wherein said treated textile article exhibitsa soil release property in excess of or equal to 3.0 as measured byAATCC Test Method 130-2000 and a moisture wicking property less than orequal to 10 seconds as measured by a water-drop surface spreading testprotocol; wherein said soil release property and said moisture wickingproperties are exhibited by said treated textile article after exposureto at least 5 industrial launderings.